Highly efficient compressed air supply system

Successful energy saving project

At Zecher GmbH, we successfully realized an energy saving project in close collaboration with companies Ullner u. Ullner (partner for industry and trade) and Kaeser (manufacturer of compressors).
Initially, an efficiency consultation was carried out which included the measuring of  compressed air consumption. Amongst other things, a very high energy consumption could be observed.

In order to achieve significant energy savings and more safety for production, the decision was made to invest in a new, highly efficient compressed air generation system.
When selecting suitable suppliers for the required hardware and software, the choice fell on the company Kaeser from Coburg in Upper Franconia. The project planning and implementation including the installation was carried out in close coordination with the Paderborn-based company Ullner and Ullner.

Since the new compressed air generation system went into operation, our production has been supplied with two compressed air line networks and two different pressure levels. Two compressors from the SK and ASK series are responsible for supplying the plasma coating systems, while five 55 kW CSD 105 screw compressors are responsible for the second network. Three energy-saving refrigeration dryers, various filters and activated carbon adsorbers were also installed.

The heart of the system is the control system. The Sigma Air Manager 4.0 controls the compressed air consumption and the compressors are controlled as energy-efficiently as possible. This translates into a potential saving of electricity costs of around 20,000€ per year. Another advantage is the integrated heat recovery. The heat is fed back into the existing building´s heating system and then used to heat up water.

The new system reduces the burden on our environment by 115,064 kg of CO² every year, which has been testified accordingly in the form of a certificate issued by Ullner & Ullner.

The investment volume for the plant amounted to around a quarter of a million euros, with 40% of the costs being covered by BAFA funding. This means we will see a return on our investment within the next four years.